RO反渗透系统操作维护培训资料.doc

反渗透系统操作维护培训资料 海得科膜分离技术(北京)有限公司上汽通用五菱青岛项目反渗透系统操作维护培训资料DI Water System Training Manualfor SGMW-QINGDAO 海得科膜分离技术（北京）有限公司Hydrotech Separation Technology Co.,Ltd.2008年2月目 录1.0概要 General22.0反渗透原理 Principle of Reverse Osmosis32.1【反渗透原理】How Reverse Osmosis works32.2卷式复合膜元件的外形结构图 Spiral Wound Element Configuration52.3反渗透系统主要术语 Major Glossary52.4影响RO膜性能的因素 Factors Influencing RO Performance62.5水处理系统原水水质分析主要项目Major Item of RO Feed water Analysis83.0 DIRO系统介绍 Introduction of DIRO System93.1 简介 Introduction93.2 系统流程简介 Introduction of system flow chart93.3 预处理系统 Pretreatment system103.4 反渗透装置 RO equipment174.0 系统维护 RO System Maintenance25一、前处理设备的维护 Pretreatment unit maintenance25二、反渗透装置维护 RO unit maintenance25三、反渗透膜的维护 RO membranes maintenance26附1：清洗液配方 Adjunct 1: Simple cleaning solutions29附2：反渗透膜污染的特征及处理方法 RO membrane fouling character and cleaning method305.0故障分析 Trouble Analysis31附: 1. 工艺原理图及相关图纸2. 运行记录表1.0概要 General 该手册提供了海得科膜分离技术（北京）有限公司制造的反渗透纯水系统重要运行操作信息，仅上汽通用五菱青岛项目（SGMW）使用。This document provides the necessary information for proper operation of the Hydrotech Separation Technology Co,Ltd RO water treatment system for SGMW-QINGDAO。海得科膜分离技术（北京）有限公司提供的整套系统是先进而可靠的，操作中应严格按照要求的运行压力、温度、原水进水水质条件等参数要求运行。The Hydrotech RO system is advanced and dependable which must be operated within specified limits of exposure to pressure, temperature, process feed water quality.整套系统除反渗透主机外，还包括辅助设备，如水箱、水泵、预处理过滤器等，该辅助设备的正常运行是整套系统安全运行的保证。The RO system is part of a larger process which includes extensive ancillary equipment, such as water tanks, transfer pumps and pre-filters. The system operator must know if the ancillary equipment is operating properly in order to successfully operate the RO system.系统操作人员需要经过海得科公司专业技术人员的培训，并严格按照操作规范操作系统。Training for all system operators is essential. The operators are required to understand and follow all operating guidelines. 操作人员应做好系统运行操作日常记录工作，以便及时发现问题并解决问题。操作运行记录表由海得科公司提供。Operators are also required to monitor the system regularly and keep an accurate written log of all operating parameters. Log sheets masters are provided by HYDROTECH.2.0反渗透原理 Principle of Reverse Osmosis2.1【反渗透原理】How Reverse Osmosis works渗透：稀溶液中的水分子通过半透膜（反渗透膜）向浓溶液中扩散的现象，称为渗透。Osmosis: The phenomenon of osmosis occurs when pure water flows from a dilute solution in one compartment through the semipermeable membrane（RO membrane） into a higher concentrated solution.渗透压：某溶液在自然渗透的过程中，浓溶液侧液面不断升高，稀溶液侧液面相应降低，直到两侧形成的水柱压力抵消了溶剂分子的迁移，溶液两侧的液面不再变化，渗透过程达到平衡点，此时的液柱高差称为该溶液的渗透压。Osmotic pressure: During osmosis, causing a rise in the compartment of the higher concentrated solution. The water flow will stop when the pressure of the column of the concentrated solution equals to the difference in chemical potential between the two aqueous solutions. The equilibrium point of the water column height in terms of water pressure against the membrane is called osmotic pressure. 反渗透原理：即在进水水流（浓溶液）侧施加一定的压力以克服自然的渗透压，当高于自然渗透压的操作压力施加在进水水流侧时，水分子自然渗透的流动方向就会逆转，进水（浓溶液）中的水分子部分通过膜成为稀溶液侧的净化产水，形成与渗透相反的现象，称为反渗透。Reverse osmosis: If a force is applied to the concentrated solution column, the direction of water flow through the membrane can be reversed. This phenomenon is called reverse osmosis, and this reversed flow produces pure water from the concentrated solution.见下图所示：(illustrated in the Figure below)半透膜RO membrane半透膜RO membrane半透膜RO membrane 渗透压Osmotic pressure渗透及渗透平衡状态Osmotic Equation State加压Pressure浓溶液Concentrated稀溶液Dilute Solution稀溶液Dilute Solution浓溶液Concentrated浓溶液Concentrated稀溶液Dilute Solution 反渗透状态RO State初始状态Begin State【反渗透过程】根据反渗透原理可知，渗透和反渗透必须与具有允许溶剂（水分子）透过的半透膜联系在一起时,才会出现渗透现象和反渗透操作，反渗透过程如下图所示。Process of reverse osmosis: According to the principle of reverse osmosis, we knew that osmosis and reverse osmosis must through RO membrane to process. The process of osmosis is illustrated in the figure below.*反渗透膜-允许溶剂分子透过而不允许溶质分子透过的一种功能性的半透膜称为反渗透膜。Reverse osmosis membrane(RO membrane)-The semi-permeable membrane that the solvent molecule is allowed transit but the solute molecule is un-allowed transit. *反渗透膜元件-将反渗透膜与进水流道网格、产水收集流道、产水管和抗应力器等用胶粘剂组装在一起，能实现进水与产水分开的反渗透过程的最小单元称为膜元件。RO membrane element-The minimum cell that consist of RO membrane、feed water channel spacer、permeate channel spacer、permeate collection tube and end cap etc.*反渗透膜组件-膜元件安装在受压的压力容器外壳内形成膜组件。RO membrane subassembly-Put the RO membranes in the pressure vessel, formed RO membrane subassembly. *反渗透装置-由反渗透膜组件、仪表、管道、阀门、高压泵、保安过滤器、就地控制盘和机架组合在内的可单独运行的成套单元设备称为反渗透装置，反渗透过程通过反渗透装置来实现。 Reverse osmosis equipment-Consist of RO membrane subassembly, meter, tube, valve, high pressure pump, cartridge filter, control panel and shelf etc. The RO process is actualized by RO equipment.*反渗透系统-为特定的水源条件和产水要求设计的，由预处理、加药、升压泵、水箱、反渗透装置和电气仪表连锁控制等组成的系统。Reverse osmosis system-System design for given feed water source and final products, the whole system consist of pretreatment, chemical dosing system, high pressure pump, water tank, RO equipment and control panel etc.进水Feed water浓水Concentrated waterRecovery(%)= Feed FlowPermeate Flow100进水盐浓度渗透液盐浓度100100-脱盐率 (%)=产水Permeate water高压泵High pressure pump半透膜RO Membrane回收率(%) =Permeate Salt Concentration100Feed Salt ConcentrationSalt Rejection(%)= 100-2.2卷式复合膜元件的外形结构图 Spiral Wound Element Configuration进水流向Feed Water进水流道网Feedwater Channel Spacer浓水Concentrate产品水Permeate water产品水流道网Permeate Channel Spacer中心集水管Permeate Collection TubeRO膜RO membrane2.3反渗透系统主要术语 Major Glossary【回收率】指膜系统中产水量与进水量之比，以分数或百分比表示。【Recovery】-The ratio of product quantity over the feed quantity, given as fraction or in percent.【脱盐率】-通过膜从系统进水中除去溶解性成份浓度的百分率。【Salt rejection】-The ability of the membrane to hinder certain elements from passing through, Expressed as 1 minus the ration between the concentration in the product and the feed.【透盐率】-脱盐率的相反值，它是进水中溶解性成份透过膜的百分率。【Salt passage】-The concentration of a compound in the permeate related to its average concentration on the feed side.【渗透液】-经过膜系统产生的净化产品水。【Permeate】-The portion of the feed which passes through the membrane, also called product.【通量】-单位膜面积上透过液的流量，通常以每天每平方英尺加仑数表示（gfd）。【Flux】-Permeate flow rate per unit membrane area, expressed commonly as GFD.2.4 影响RO膜性能的因素 Factors Influencing RO Performance【压力】PRESSURE如图1所示，渗透液的总溶解固体随着作用压力的增加而减少，渗透液流通量则随之增加。With increasing effective feed pressure, the permeate TDS will decrease while the permeate flux will increase as shown in figure 1. 脱盐率rejection(恒定通量)脱盐率 rejection产水通量flux产水通量 flux(恒定压力)图1.进水压力对通量和脱盐率的影响 压力Pressure 温度Temperature图2.进水温度对通量和脱盐率的影响 Figure1.Performance vs.feed pressure Figure2.Performance vs.feed temperature 【温度】TEMPERATURE如图2所示，膜元件对进水温度的变化非常敏感，随着水温的增加，水通量几乎线性地增大，这主要归功于穿过膜的水分子的扩散能力随温度增加而增大。同时，增加水温会导致脱盐率降低或透盐率增加，这主要是因为盐份透过膜的扩散速率会因温度的提高而加快所致。If the temperature increases and all other parameters are kept constant, the permeate flux and the salt passage will increase. See figure 2. 【供水盐浓度】FEEDWATER SALT CONCENTRATION图3显示了供水盐浓度对渗透液流通量与脱盐率的影响。Figure 3 shows the impact of the feedwater salt concentration on the permeate flux and the salt rejection. 脱盐率rejection脱盐率 rejection水通量flux水通量 flux 进水盐浓度 回收率RecoveryFeedwater salt concentration 图4.增加回收率对通量和脱盐率的影响图3.进水盐浓度对通量和脱盐率的影响 Figure3.Performance vs.feedwater Figure4.Performance vs.recovery vs salt concentration【回收率】RECOVERY回收率为渗透液流量与进水流量的比值。渗透液流通量随着回收率的增加而减少，当浓缩液的渗透压高到与进水的压力相同时则停止。脱盐率随着回收率增加而减少(见图4)。The recovery is the ratio of permeate flow to feed flow. In the case of increasing recovery, the permeate flux will decrease and stop if the salt concentration reaches a value where the osmotic pressure of the concentrate is as high as the applied feed pressure. The salt rejection will drop with increasing recovery.2.5 水处理系统原水水质分析主要项目Major Item of RO Feed water Analysis基于以上对反渗透原理和影响因素的介绍可知，对于一套工艺先进、设计合理的反渗透系统来说，运行的稳定性与原水的水质变化情况息息相关，因此，在运行中应能全面了解原水的水质变化，尤其是地表水水源的水质会随季节变化而变化。对于这样的系统，建议做好水质常规分析工作，并能根据原水水质变化，准确判断系统运行的情况。水源常规分析项目：Item of feed water analysis铵离子（NH4+）总铁(Fe2+/Fe3+)亚硝酸根(NO2-)活性二氧化硅(SiO2)钾离子(K+)锰离子(Mn2+)硝酸根(NO3-)硬度(Total hardness)钠离子(Na+)铜离子(Cu2+)氯离子(CL-)二氧化碳(CO2)镁离子(Mg2+)锌离子(Zn2+)氟离子(F-)游离氯(Free chlorine)钙离子(Ca2+)铝离子(Al3+)硫酸根(SO42-)PH钡离子(Ba2+)碱度(M-value)磷酸根(PO43-)总固体含量(TDS)锶离子(Sr2+)碳酸氢根(HCO3-)硫化氢(H2S)水温(Temperature)铁离子(Fe2+)碳酸根(CO32-)胶体二氧化硅(SiO2)浊度(NTU)生物耗氧量(BOD)化学耗氧量(COD)总有机碳(TOC)污染指数（SDI）3.0 DIRO系统介绍 Introduction of DIRO System3.1 简介 Introduction本套DIRO系统是专为上汽通用五菱青岛项目提供合格的工艺水而设计的，其原水水质为青岛市市政自来水。This DIRO system is designed for SGMW-QINGDAO PAINT PLANT，The feed water is used municipal water of QINGDAO city.因空调用水和电泳线用水的水质不同，我公司提供了两套反渗透系统，其中一套一级RO系统设计产水量为47m3/h(20),其进水为原水，产品水进入一级RO纯水箱储存，供空调、打磨室、修补室等生产用水。另外一套RO系统设计产水量为23m3/h(20)，该系统的进水为一级反渗透的产品水，即对一级反渗透的产品水做进一步的脱盐处理，以达到电泳线的工艺用水要求。As the water quality is different between air-condition water and confect paint water, we design two set RO system. One set RO system designed flux is 47 m3/h(20) and its feed water is raw water, the permeate water feed in the first pass RO permeate water tank to used for air-condition and working decks with sanding operation & repair. The other one designed flux is 23 m3/h(20) and its feed water is the first RO permeate water, desalt farter the first RO permeate water to achieve the quality of confected paint water.3.2 系统流程简介 Introduction of system flow chart原水箱原水泵换热器絮凝剂 多介质过滤器 二级纯水箱 纯水泵 UV杀菌 精密过滤器 用水点 还原剂 活性炭过滤器 二级反渗透装置阻垢剂 精密过滤器 二级高压泵 PH调节一级高压泵 二级提升泵 一级反渗透装置 一级纯水箱 纯水泵 UV杀菌 用水点 清洗装置 Raw water tank Raw water pumpHeater Pure water pump II UV Cartridge filter To used pointPAC Sand filter Pure water tank IIReducing Active carbon filter RO system IIAnti-scale Cartridge filter High pressure pump II PH dosing systemHigh pressure pump I Feed pump II RO system I Pure water tank I Pure water pump UV To used point CIP system 3.3 预处理系统 Pretreatment system本系统的预处理部分包括原水箱、原水泵、絮凝剂加药装置、还原剂加药装置、多介质过滤器、活性炭过滤器、保安过滤器、阻垢剂加药装置等设备。其主要设备的性能参数及操作步骤详述如下：The pretreatment system include: raw water tank, raw water pump, PAC dosing equipment, reducing agent dosing equipment, sand filter, active carbon filter, cartridge filter, anti-scale dosing equipment etc. The performance of primary equipment and its operate process shows as follow.一、 多介质过滤器Sand filter本系统设有一台多介质过滤器，直径2800mm，材质为不锈钢。填料为多种级配石英砂，层高1400mm。它可将水中的悬浮物、凝聚的片状物及胶体等除去。保证出水达到反渗透的进水要求。该过滤器的设计产水量为64m3/h，设计流速为10.5m/h。过滤器采用手动/自动操作，本体阀门配置气动蝶阀，进出口母管上设有压差开关，当进出口压力差达到设定值（0.07Mpa）时，控制盘发出报警信号，提醒运行人员需要对该过滤器进行反洗，以恢复过滤器的性能。This system has a sand filter, 2800mm diameter, the material is stainless steel. This filter can remove the suspended and colloidal particles by its filter media. Its product water quality can achieve the request of RO feed water. The design filtration flux is 64 m3/h,flow rates are 10.5m/h. The filter is designed manual and automatism, the valves are pneumatic butterfly valve, and there are differential pressure switch on its inlet and outlet pipes, When the differential pressure increase between the inlet and outlet of the filter is 0.7 bar, the panel can give a backwash alarm. The quatity of filter can be revive by backwash and rinse the filter to carry away the deposited matter. (一)运行步骤 Operate process 手动方式： Manual mode1、 打开进水阀V11和排气阀V16；Open the inlet valve V11 and exhaust valve V16;2、 启动原水泵；Open the raw water pump;3、 待排气阀V16出水后表明过滤器内已充满水，打开运行出水阀V12，同时关闭排气阀V16；Open outlet valve V12, and close exhaust valve V16 When the exhaust valve V6 discharge water; 设备开始正常运行，运行时流量保证不大于64m3/h。 The filter operate, ensure the flow rate dont exceed 64m3/h. 说明：过滤器本体配置阀门为气动阀，正常运行时采用自动运行方式，手动方式仅作为系统初次投运或程序故障时使用，使用时只要控制气动阀的电磁阀即可实现阀门的开启。 Explain: The valve of the filter is pneumatic valve, natural operate is automatic, manual operate only used in the filter first running or program failure. Manual operate by control the solenoid valve of the pneumatic valve. 自动方式：Automatic mode 人为按下控制盘上的运行按钮，该过滤器上的进出口阀门及相应的原水泵即自动打开进入运行状态。 The inlet valve and outlet valve and raw water pump will automatic running when the running button on the panel is pressed. (二)反洗步骤 Anti-flush process砂滤器必须定期反洗，以保证其过滤效果。反洗时间可根据运行时间或进、出口的压力差（正常达到0.07MPa）来确定.反洗步骤如下：The sand filter must be anti-flush termly, in order to recover the capability. The anti-flush time is basis on the difference pressure of inlet and outlet. ( usely achieve 0.07 MPa) .The anti-flush process as follow:手动方式：manual mode1. 关闭原水泵；Close the raw water pump;2. 关闭进水阀V11和出水阀V12，打开排水阀V15，将水面降至上部视镜处的位置（水面高出滤料层约200mm）;Close the inlet valve V11 and outlet valve V12, open the drain valve V15, put the water drop to the looking glass(water exceed medium 200mm); 3. 关闭排水阀V15，打开排气阀；Close the outlet valve V15,open the exhaust valve;4. 启动两台原水泵；Open two raw water pumps at same time;5. 缓慢打开反洗进水阀V13，水从底部进入过滤器，当排气阀有水流出时，关闭排气阀；Open the anti-flush inlet valve V13 slowly, water enter the filter from the bottom, when the exhaust valve drained, close the exhaust valve;6. 打开反洗排水阀V14,使滤层膨胀40-50%，保持10-20分钟；Open the anti-flush drain valve V14, expand the medium layer achieved 40%-50%, keeping 10-20 minutes;7. 关闭反洗进水阀V13和排水阀V14，同时关闭原水泵，静置2分钟；Close the anti-flush inlet valve V13 and drain valve V14, close two raw water pumps at the same time, deposited 2 minutes;8. 正洗时，打开进水阀V11及正洗排水阀V15，启动一台原水泵，水由上部流入过滤器正洗，正洗5-10分钟，至出水透明（最好检测SDI值合格）；When the filter flush, open the inlet valve V11 and flush drain valve V15, open the one of raw water pump, water enter the filter from the top, flush the filter 5-10 minutes, as soon as the discharge water is clarity( SDI5);9. 开出水阀V12，关闭排水阀V15，过滤器投入正常运行。Open the outlet valve V12, close drain valve V15, the filter come into use. 自动方式：Automatic mode当电控系统发出报警信号提示过滤器应进行反洗时，操作人员可根据现场情况确定反洗时间。具体步骤如下：The operator will confirm the anti-flush time by the locale condition when the control system alarm to remind of the filer must to be anti-flushed. Particular process as follow:按下反洗按钮，过滤器本体上的自动阀门按程序表所示自动开关，并完成反洗程序。Press the anti-flush button, the valves of filter will automatic open or close according to the follow program table, and complete the anti-flush program. 二、活性炭过滤器 Active carbon filter本系统设有一台活性炭过滤器，直径2800mm，材质为不锈钢。填料为高质量的果壳活性炭，层高1400mm。它的作用是吸附原水中的有机物及游离余氯，以保证RO膜元件免受有机物及氧化物的侵蚀。该过滤器的设计产水量为64m3/h，设计流速为10.5m/h。过滤器采用手动/自动操作，本体阀门配置气动蝶阀，进出口母管上设有压差开关，当进出口压力差达到设定值（0.07Mpa）时，控制盘发出报警信号，提醒运行人员需要对该过滤器进行反洗。This system has a active carbon filter, 2800mm diameter, the material is stainless steel. The media is activated carbon,layer high 1400mm. This filter can adsorb the organic and free chlorine of raw water by its filter media, to assure the RO membrane being un-oxidation. The design filtration flux is 64m3/h,flow rates are 10.5m/h. The filter is designed manual and automatism, the valves are pneumatic butterfly valve, and there are differential pressure switch. When the differential pressure increase between the inlet and outlet of the filter is 0.7 bar, the panel can give a anti-flush alarm. 运行及反洗步骤同多介质过滤器。Running ans anti-flush process as the sand filter.三、保安过滤器 cartridge filter保安过滤器又称精密过滤器, 通常内装精度为5mm 熔喷滤芯。它的主要作用是当前部的过滤器在运行时出现短暂的不正常情况时，作为最后一道把关的设备，保证大于5mm的颗粒物质不会进入反渗透膜元件中，保护反渗透膜元件不被损伤。该系统保安过滤器内装40”的熔喷滤芯20只。过滤器的外壳为不锈钢材质。The cartridge filter is named exact filter, usually setting 5 micron polypropylene filters. It is a safety device to protect the membranes and the high pressure pump from suspended particles as the last step of a pretreatment sequence. This cartridge filter setting 20 filters with 40 inches length. The cartridges material is stainless steel. （一）操作步骤 Operation process1、打开进水阀和过滤器本体的排气阀，至排气阀有水流出，此时表明精密过滤器内已充满水；Open the inlet valve and the exhaust valve of filter, till water drains from exhaust valve, indicated the filter is full;2、打开出水阀，同时关闭排气阀，此时，过滤器正常运行。Open the outlet valve, close the exhaust valve, the filter start running.（二）滤芯的更换步骤 The filters replaced 设备运行后，应库存备用滤芯。在操作过程中，过滤器的进出口压差达到1Kgf/cm2以上时，以及设备连续运行三个月后，就必须更换新的过滤芯。不能试图使用清洗过的滤芯，要配置与原设备中同规格的滤芯。不按要求更换滤芯，将不能保证设备性能。具体操作步骤如下：The filters must be stocked when the system is in operation. The filter must replaced before the pressure drop has increased to the permitted limit (usually 1.0kgf/cm2),but latest after 3 months. Back-flushable filters are not recommended because of their lower efficiency and higher bio-fouling risk. The capability will not be assured if not according to request. The operate process as follows:1、停运后，打开排污阀，将保安过滤器内的水排尽； After stop running, open the drain valve, complete drain water.2、旋开上部封头的封闭螺丝，取下上封头； Unscrew the seal screw of the close over, take off the close over;3、旋开中心管螺母，取下滤芯压盖； Unscrew the nut on the center tube, take off the impacted cap of the filters;4、取出滤芯，更换新的滤芯，并按原安装方式安装完